Summer TRAINING REPORT

ON

AUTO-CAD

FROM MANIk SHARMA

 Scope of CAD/CAM/CAE

Integrated CAD/CAM/CAE Softwares like Pro/Engineer, I-DEAS & CATIA

help manufacturers optimize product concept early in Design process,
enabling them to significantly improve product quality, while reducing
product development time and cost

Moreover people having 3D CAD/CAM/CAE knowledge have better

chances of growth, immediate employability after completion of course,
graduation and chances of jobs abroad.

As the market economy opens more and more it has become extremely
competitive and with this state of economy, skilled people play the most
important role in organization. Hence it becomes imperative on the part of
top Tool Room Training centers and Engg. Colleges to especially look for
new initiatives towards improving the skills and knowledge of students.

An emerging trend of Engg. Education in Tool Room and the world is the
rapid incrementation of CAD/CAM/CAE software as an essential part of
curriculum.
The primary reasons for this trend are enumerated as follows:

Rapid shift from manual Design and Production system of Engg. Industry
to highly productive quality and cost effective CAD/CAM/CAE system.
In fact most of Tool and Die, Automotive, Heavy Engg., Industrial
Equipment industry etc. in India and the World are totally working on
CAD/CAM/CAE equipment. In continuation in above points many of
companies as recruiters are looking at CAD/CAM/CAE knowledge as
part of essential profile of recruiting students.

Knowledge of CAD/CAM/CAE system shall be an added weapon for

students seeking admission to post graduate M.S. courses and jobs
abroad.

These CAD/CAM/CAE systems shall prove to be an excellent tool for

Industry, Research setup for Professors and Academically Bent Students.
The question, Which are the industries that need more skilled man power
and what for these segments skill sets are available, such of these
segments are:

Tool Room Process M/C Heavy Engg. Industries

M/C Tool Defence
Automobile Auto Ancillaries
WORKING WITH CAD/CAM/CAE TECHNOLOGY
Essentially design is a decision making process where the
discretion and knowledge of the designer play a great role. While man still
finally controls decision-making, the computer has served to ease the
designers task.

CAD CAM CAE

TOOL PATH SIMULATION

MASTER GENERATION
MODELER

SHEET METAL MOLD PIPE

DESIGN DESIGN
DESIGN

STATIC ANALYSIS DYNAMIC ANALYSIS

(WHEN BODY IS IN (WHEN BODY IS IN
STATE OF REST) STATE OF MOTION)
GEOMETRIC MODELLING: -
Design involves the development of the shape and dimensions of a
component. During designing several factors are to be considered
simultaneously. Some of them are stress requirements, method of
manufacture. Geometric modeling is the first step in CAD. A geometric
model is created on the screen using different techniques. Once creating this
model can be easily altered in geometry and configuration to yield a
satisfactory shape. The next step is deciding on the exact dimensions. The
results of geometric modeling will further be use by CAM in the preparation
of NC tapes for the component.

ENGINEERING ANALYSIS: -
The most important function of CAD is engineering analysis.
Engineering analysis basically involves deciding the exact dimensions of the
component. These values have to be arrived at by analyzing the component
in terms of the loads it has to withstand in function. CAD provides
sophisticated method like the finite element technique. Unsatisfactory design
may require several iteration of the whole process. The computer scores over
the human in its capabilities of rapid information retrieval, numerical
processing and repeating a process without fatigue.

SIMULATION: -
Simulation, in the CAD/CAM context, means duplicating on the
video screen a replica of the actual physical situation the designed
component is likely to be in. for instance, an aeroplane will be subjected to
wind loads. In the conventional method, the aeroplane will be tested in a
wind tunnel using a prototype. This is an expensive and inflexible process,
expensive because of the physical construction of the wind tunnel and the
prototype, inflexible because it may not be possible to test various sizes and
shape under a set of test condition. Computer simulation gets rid of both
these limitations. It involves the testing of a graphic model whose size and
shape can be varied at will. Computer simulation does not completely do
away with prototype testing. A near perfect shape can be determined using
simulation, which can later be tested with a prototype under test conditions.

DRAFTING: -
The logical step would be to produce a drawing of the component. A
drawing is dispensable for the production of the component. Not only the
components designed by engineering analysis, but also complex layouts,
assemblies can be created interactively and plotted in about one tenth of the
normal time. Automated drafting has resulted in enormous productivity
gains in terms of time, labour and expenses.

EXPERT SYSTEMS: -
The latest development in CAD is the use of Expert systems. An
Expert system has an intelligent data-base called knowledge base and
reasoning logic. It may contain, for example, the details of the breakdowns
that occurred in the industry. On a later date, the user has only to feed in the
conditions under which a breakdown occurred. The expert system discovers
the reason for the breakdown. This is only one application of expert systems.
Wherever decision making under multiple constraints is involved expert
systems are used as logic support systems.
SYSTEM DESIGN CYCLE (Conventional design cycle)
For solving any design problem or engineering problem, the
general procedure may be followed.

RECOGNITION OF A NEED

SPECIFICATION AND
REQUIREMENTS

FEASIBILITY STUDY

CREATIVE DESIGN
SYNTHESIS

PRELIMINARY DESIGN AND

DEVELOPEMENT

DETAILED DESIGN

PROTOTYPE BUILDING
AND TESTING

DESIGN FOR PRODUCTION

PRODUCT RELEASE
RECOGNITION OF A NEED
This aspect of design can have its origin in many numbers of
sources. Customer reports on the product function and quality may force a
redesign. The starting point of a design project is a hypothetical need which
may have been observed in socio-economic scene. The need may be existing
or may not yet exist, but the evidence may be existing that the need is latent.
The following points will help at this stage:

1. Study the nature of the need.

2. Establish the need reasonably well to the extent possible.
3. Make primitive statement of need.
4. Do reconnaissance study with respect to qualitative and
quantitative aspects.

SPECIFICATION AND REQUIREMENTS

Once a need has been established, its requirements must be
carefully spelled out. Very often the specifications are stated in such general
terms as to indicate that the consumer has only a vague idea of what he
wants. In these requirements design and performance requirements are
carefully stated. Also, the specifications are prepared keeping in mind the
production competence and capability of the company.

FEASIBILITY STUDY
Once the problems need has been established and the
specifications have been prepared, accepted and submitted, the feasibility
study is done. The purpose of this study is to check the possibility of success
or failure of the purposed project both from technical and economic
standpoint. In this study, various questions are to be answered.
1. Is any natural law being defied?
2. Are some of the specifications beyond what is technically
available at present?
3. Is there any dependence on source materials?
4. Will the cost of the end product be too high?

The persons doing the feasibility study will be the engineers with strong
design background, knowledge of engineering science, a good knowledge of
material usage, knowledge of production methods and requirements of the
sales department.

CREATIVE DESIGN SYNTHESIS

Once the feasibility of the design is established, the creative
design synthesis has to be done. Here, the designer can act as engineer,
inventor, artist all in one, because now he is called upon to create.
The quantities of the new design will be:
1. The quality of newness or uniqueness.
2. Things, which are either useful or appreciated, are called creative.
Creative things are sometimes either purposeful or beautiful or
both.
3. The third quality in the design solution will be that it will have
simplicity. A solution having the qualities of newness and useful or
appreciated but complex would not be known as a creative solution.

PRELIMINARY DESIGN AND DEVELOPMENT

After the process of creativity design is complete, there will be one
or more possible designs that satisfy the given set of specifications and
requirements. It then becomes necessary to decide which of the solutions to
choose for the preliminary design and development stage. Note, this stage is
primarily concerned with checking the validity of the functional and overall
size requirements of the specifications.
The stages of the preliminary design can be summarized as below:
1. Selection of the most useful solution from the several suggested
solutions.
2. Formulation of useful model preferably mathematical for this
selected solution.
3. Analysis of this model.
4. Prediction of performance.
5. Preparing layout of the selected solution, making a check for its
function.

DETAILED DESIGN
Many designers often miss many of the activities of the detailed
design phase of the design process, particularly for smaller jobs, because so
much of the detailing in the sense of component design is already done in
the preliminary design phase. This phase of the design work consists of two
major activities:
 (1) Detailing the parts, component and their assembly.
(2) Going into sufficient details of manufacture in implementing the
design.

The second phase as indicated earlier requires a good knowledge of

manufacturing process. The method of manufacturing should be such that
the following are avoided.
(1) Heavy weight of material
(2) Reclamping of work
(3) Special purpose tools
(4) Finishing operations

PROTOTYPE BUILDING AND TESTING

After completing all the details, the sub-assemblies and assembly
drawings including the materials and parts list, the completed design is sent
to the prototype or model shop for fabrication. At this juncture the parts are
fabricated, commercial components are purchased, and the machine or
system, after having been assembled, is ready for evolution and testing. This
testing can help in:
1. Producing acceptable performance
2. To generate new design information
3. To develop improved design concepts
4. To increase validity of the results.

DESIGN FOR PRODUCTION

In addition to being functionally sound, a product must have sales
appeal and must be competitive in price. In order for a product to be made
economically, it must be designed so that the most appropriate material and
processes will be utilized. This is called design for production. For large
scale manufacturing, any of these processes may be more economical than
individual part machining.

PRODUCT RELEASE
Production prototype are usually made and tested, and any
drawback that can be easily corrected is generally referred back to
preliminary design and development or to detailed design for alteration.
ADVANTAGES OF CAD

CAD can make a draft men much more efficient. Depending

upon the drafting task, two to ten times productivity improvement is not
uncommon when using a CAD system .The following are the advantages of
using CAD over manual drafting: -

REVISIONS: -
One of the most time-consuming tasks that a draft man performs is
making changes to existing drawings. With a CAD system, revisions are
much faster than manual methods. After a drawing has been completed, it is
stored and can be recalled at any time to make changes easily.

REPITITION: -
Simple symbols or more complex ones , are created by drawing
them with the CAD system and storing them away to be used at any time.
Once a drawing has been produced and stored in the computers memory, it
does not have to be drawn again if it is part of another drawing. Parts of
previous drawings can be combined to produce new drawings.

ACCURACY: -
Dimensions are keyed-in using the computer keyboard or menu
instead of reading a scale. Mating parts can be checked for fit by having the
computer match the parts on the screen before hard copies are produced.

SPEED: -
In almost all areas of drafting, CAD is faster than manual drawing.
This is especially true as the operator becomes more proficient through
continued use of the system

NEATNESS: -
After the drawing has been produced on screen, it can be drawn on
paper with a plotter. The mechanical plotting of a drawing produces clean,
accurate and neat drawings using proper line weight and consistency, and
sharp, consistent lettering.
COST: -
In the past, CAD systems were an expensive alternative to manual
drafting, and only major industrial corporations could afford them. Now,
because of reduced cost of memory, increased competition, and improved
software and computer technology CAD systems are affordable to most
drafting-design offices.

DIFFERENT TYPES OF CAD/CAM SOFTWARE

1. INTEGRATED CAD/CAM SYSTEM - Pro/engineer, I-DEAS

CATIA, UNIGRAPHICS are integrated CAD/CAM system. We can
do design/ analysis/ generation of tool path in same environment.

2. Point/Standalone solution- Softwares, which give only one

solution out of DESIGN, MANUFACTURING &
ANALYSIS are called point solution software. Like AUTO-
CAD gives only drafting solution, master cam gives
manufacturing solution& ANSYS, NASTRAN, ADAMS,
ABAQUS gives only analysis solution.
Why industries switches towards 3-d technology

Because 3-d model is centreled to all the activities pertaining to

analysis,manufacturing,product concept& customer requirements.